Method of making brick panels

ABSTRACT

A method of manufacturing a brick panel includes the steps of forming a bed of concrete, arranging the bricks in a plurality of rows, moving the rows of bricks over the exposed surface of the bed of material, sequentially depositing the rows of bricks in the bed of concrete, and sequentially partially embedding the rows of bricks in the surface of the concrete, as by vibratory blows.

Aug. 28, 1973 J. M. YOUNG TAL 3,755,521

METHOD OF MAKING BRICK PANELS Original Filed Aug. 19, 1968 4Sheets-Sheet l Aug. 28, 1973 J. M. YOUNG EI'AL METHOD OF MAKING BRICKPANELS 4 Sheets-Sheet 2 Original Filed Aug. 19, 1968 Aug. 28, 1973 J,YOUNG ETAL METHOD OF MAKING BRICK PANELS 4 Sheets-Shet 3 Original FiledAug. 19, 1968 Aug. 28, 1973 J. M. YOUNG ETAL METHOD OF MAKING BRICKPANELS 4 Sheets-Sheet 4 Original Filed Aug. 19, 1968 United StatesPatent 3,755,521 METHOD OF MAKING BRICK PANELS James M. Young, 3402 W.Wells St. 53208, and George 0. Whitney, Milwaukee, Wis. (868 BaywayBlvd., Apt.

M-312, Clearwater, Fla. 33515) Original application Aug. 19, 1968, Ser.No. 753,500. Divided and this application Mar. 25, 1971, Ser. No.128,123

Int. Cl. B28b 1 08, 1/16 US. Cl. 264-69 11 Claims ABSTRACT OF THEDISCLOSURE A method of manufacturing a brick panel includes the steps offorming a bed of concrete, arranging the bricks in a plurality of rows,moving the rows of bricks over the exposed surface of the bed ofmaterial, sequentially depositing the rows of bricks in the bed ofconcrete, and sequentially partially embedding the rows of bricks in thesurface of the concrete, as by vibratory blows.

This is a divisional application of Ser. No. 753,500, filed Aug. 19,1968.

BACKGROUND OF THE INVENTIONFIELD OF THE INVENTION The present inventionrelates to a method for making masonry or concrete structures,particularly faced wall structures.

BACKGROUND OF THE INVENTION- DESCRIPTION OF THE PRIOR ART Recent trendsin building construction techniques have favored the construction ofbuildings from steel framing which may be pre-cut or prefabricated on amass production basis and then assembled or erected at the individualjob site. The walls of such buildings comprise sheets or panels of metalor other materials attached to the steel framework. Such panels havebeen formed from pre-cast concrete or other cementitious materials sothat the finished steel frame building is similar, in appearance, to oneconstructed by conventional methods. By contouring the forms in whichthe panels are cast, panels having an outer surface resembling, orsimulating, ordinary building materials used in walls, such as stucco,may be provided.

It has long been desired to provide such panels or walls with an outersurface resembling laid brick. While the concrete form may be contouredto resemble brick, the distinctive color of brick has required eitherthat the concrete be colored in some manner or that the finished panelbe painted. The first of these approaches fails to provide the economydesired of precast panel construction, while the second is lacking indurability.

SUMMARY OF THE PRESENT INVENTION It is, therefore, the object of thepresent invention to provide a method providing a precast panel with asurface having the appearance of laid brick.

The present invention provides a method for embedding or implantingobjects, such as rows of bricks; in the exposed surface of a'bed ofcementitious material, such as wet concrete, so as to provide, uponcuring of the concrete, a panel with a surface having the appear ance oflaid brick.

The bed of material is formedin aforrn or other receptacle. A surfacingmachine, movable along the form is positioned over the form. The machineincludes a frame having .a support means mounted inside an endless'beltor track having a plurality of track sections for receiving the rowsofbrick. The track iscarried by the support means for movement in anorbital path with respect to the frame. The support means positionsaportion of the track adjacent the exposed surface of the bed of materialfrom which portion the bricks maybe deposited in the surface. I h v w .1f A driving means, mounted'on the frame,ifmo vesj'the frame along theform and moves the track in its orbital path to add new, brick ladentrack sections to the portion of the track adjacent the exposed surfaceof the concrete and remove the empty sections from that portion, so thatthe deposition of rows of brick continues as the machine moves along theform. A means to assist the embedment of the brick in the surface of thematerial, such as a vibrating means, may be provided on the frame.

It is a further object of the present invention to provide a method formaking such a panel which utilizes actual brick, thereby lendingauthenticity and durability to the panel surface.

It is yet another object of the present invention to provide a methodfor making such panels rapidly and with low labor cost.

It is a still further object of the present invention to provide amethod for making such panels which may utilize split brick, therebyusing both faces of the brick and substantially reducing material costs.a

The method of forming a panel with embedded objects in the surfacethereof commences with the forming of the bed of material in the form.If desired, collapsible cores may be inserted in the material to reducethe weight of the complete panel. The material is struck off in the formto provide the exposed surface.

A plurality of objects are then deposited on the surface of the materialand embedded therein, as by operation of the surfacing machine. Thespaces between the embedded objects may be filled with mortar and thematerial cured to form the completed panel.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of asurfacing apparatus;

FIG. 2 is a longitudinal cross sectional view of the apparatus of FIG. 1showing the deposition of the objects in the exposed surface of thematerial;

FIG. 3 is a lateral cross sectional view of the apparatus of FIG. 1taken along the line 33 of FIG. 2;

FIG. 4 is a partial, lateral cross sectional view of the surfacingapparatus, similar to FIG. 3, but showing the embedment of the objectsin the surface of the material;

FIG. 5 is a detailed, partial, lateral cross sectional view showing ameans for coupling the surfacing machine to the material form;

FIG. 6 is a partial longitudinal cross sectional view showing thedetails of the endless track of the surfacing machine and the rotarysupport means therefor;

FIG. 7 is a partial perspective view of the means for embedding theobjects in the exposed surface of the material;

FIG. 8 is a somewhat schematic and diagrammatic view of the means forembedding the objects in the exposed surface of the material and of acontrol system therefor;

FIG. 9 is a detailed view of a track section forming a portion of theendless track of the surfacing machine;

FIG. 10 is a perspecive view of a portion of the means for embedding theobjects in the surface of the material.

FIG. 11 is a perspective view of a completed panel of cementitiousmaterial having a plurality of objects embedded in an exposed surfacethereof, such as may be provided by the method of the present invention;and I FIG. 12 is a perspective view of a retaining means incorporated inthe surfacing machinev for retaining the objects in the endless trackuntil deposition in the material.

FIGk 1' "shows a panel? which may be formed by the method or the presentinvention- The panel includes a substratum of "concrete C orotherceihentitous material on an exposed surface of which is embedded a'plurality of objects, suchas -br'icks -B."Panel"P may' contain bracketsBR for attaching the panel to the steel framework of the building. Thebricks B are embedded in the concrete C in a pattern such" that theexposed surface of th'e finished panel resembles laid brick having adesired 1 bond configuration, such as stretcher, header, common, orEnglish bond. In all such bond patterns, the bricks are generallypositioned in aplurality of horizontal rows, termed courses. The bricksforming any given course are separated by head joints'and adjacentcourses of brick are separated by bed joints. The joints may be filledwith mor-tar 'M so as' to give the surface of the panel the appearanceof conventionally laid brick. FIG. 11 show's',forsimplicity, a bondconfiguration in which the bricks are arranged in a plurality ofvertical rows, termed stacks.

Any of the generally available types of brick, such as common brick,pressed brick, or glazed brick, may be used in panel P. The drawingaccompanying the specification shows, in an exemplary manner, pressedbrick having a plurality of holes extendinng therethrough parallel tothe finished faces of the brick.

The concrete form The apparatus includes a surfacing machine 20 coupledto, or mounted on a form 22, as shown in FIG. 1. Form 22 may be anelongated or longitudinally extending U- shaped trough having a bottomplate 24 and a pair of laterally spaced parallel vertical sidewalls 26and 28. The ends of form 22 may be closed by bulkhead 29 which areadjustably positioned along the length of form 22 to provide a finishedpanel P of the desired length.

A plurality of collapsible cores 30 extend down the length of form 22and through the bulkheads. As shown in FIG. 3, each of the cores 30includes a bottom plate 32 and a top plate 34 having curved longitudinaledges extending toward each other. Top plate 34 and bottom plate 32 maybe retained for limited movement toward and away from each other byslotted straps 33 linked by bolts 35, as shown in FIG. 3.

The core also includes side plates 36 and 38 which are positioned toabut the top and bottom plates near their edges. The position of sideplates 36 and 38 is adjustable by turnbuckle 40 or other means.

The plates comprising cores 30 are generally constructed from a heavymaterial, such as iron or steel, to offset any tendency of the cores tofloat as concrete is poured into form 22 and around cores 30.

With side plate 36 and 38 extended, as shown in FIG. 3;mp plate 34 andbotton plate 32 are forced apart to the. limits ofv braces 33 to form arigid structure around which concrete may be poured.

By moving side plates 36 and 38 inwardly, away from the curved edges oftop and bottom plates 34 and 32 the latter plates may be moved towardeach other to collapse the core andallow its removal from. the hardenedconcrete in form 22. The holes in the panel -P formed by cores 30lighten the-panel and permitelectric wires,-

piping, and other services to be inserted through the panels and thewalls formed therefrom.

The upper surfaces of parallel, vertical sidewalls 26 and '28 of form 22contain a plurality of projections 42 spaced along the length of theWall which are used to couple the surfacing machine 20 to the form toform the surfacing apparatus. As shown in FIG. 5, each of theseprojections may comprise a bolt 44 or other means attached to the form.As hereinafter described, projections 42 serve to position surfacingmachine 20 with respect to "the exposed surface of the wet concrete C inform 22.

The surfacing machine l 'As noted in the summary, thesurfacing machine20 includes a frame, portions of which are, mounted inside an endlessbelt or track which moves in an orbital path with respect to the frame.Means are provided for mounting the frame on the form and over the bedof material, as by an engagement of a portion of the track withprojections 42 on the form.

During the deposition of brick in the surface of the material in form22, the entire surfacing machine 20 moves forward in an longitudinalpath along the form while, at the same time, the track moves in anorbital path with respect to the frame, resulting in a laying down ofadditional portions of the endless track on the form at the front of themachine and a picking up of corresponding portions off the form at therear of the machine, in the manner of a tracked vehicle. It is importantto the understanding of the apparatus of the present invention torealize that, while the machine moves forward along the form asdescribed above, the portion of the track engaging the form remainsstationary with respect to the form in the position in which it is laiddown, until it is picked up. The machine, and particularly the frameportions thereof, thus move forward with respect to the portion of thetrack in engagement with the form, or conversely, this portion of thetrack moves rearwardly with respect to the frame.

Turning now to the details of surfacing machine 20, the machine includesa main frame 50 constructed of steel channel members. Frame 50 may begenerally rectangular in shape having a pair of longitudinal members 52and 54 lying parallel to, and adjacent, vertical sidewalls 26 and 28 ofform 22, a forward lateral member 56, and a rear lateral member 58connecting the lognitudinal members.

A pair of laterally extending axles 60 and 62 are journalled atlongitudinally spaced positions on longitudinal members 52 and 54 bybushings 64 and 66 and 68 and 70. See FIGS. 1 and 2. Each of the axlessupports a rotary support means in the form of a drum or plurality ofseparate discs. The latter configuration is shown in FIGS 1, 2 and 3,wherein each axle has a disc aflixed thereto, adjacent the bushing. Axle60 supports discs 72 and 74 while axle 62 supports discs 76 and 78. Theperiphery of the discs may be covered with rubber belt 80 or othernon-slip material, as shown in FIG. 6.

An endless track or belt 82 is rotatably mounted on discs 72 and 74 and76 and 78 so that the discs are on the inside or within track 82. Thelongitudinal spacing of axles 60 and 62, and the discs supportedthereby, causes track 82 to assume a generally oval or elliptical shape,as shown in FIG. 2, having forward and rear portions abutting the discsand a lower flattened portion extending between the two sets of discsadjacent the exposed surface of the concrete C in concrete form 22. Thetrack 82 may also have an upper flattened portion extending bet-ween thetops of the two sets of discs parallel to the lower flattened portion.Track 82 is comprised of a plurality of hinged track sections 84 shownin detail in FIG. 9 and in longitudinal cross section i FIG. 6.

Track section 84 includes a lattice having 'a plurality of compartments85, sized to receive bricks B. The lattice of each track section mayinclude a compartment for one or more courses or rows of bricks B in thefinished panel P, the track section shown in FIG. 9 having suflicientcompartments for three courses of bricks, six bricks wide. The striplike members forming the compartments 85 of track section 84 also serveto separate adjacent bricks and thus form the bed joints and headjointsin the completed panel. In the following description, thelongitudinal. dimension of the compartments 85 and track sections 84 isthat parallel to longitudinal frame members 52 and 54 and the lateraldimension runs parallel to forward and rear lateral frame members-56 and58.

Each track section 84 includes an end plate 86 at either side thereofhaving an outwardly extending flange 88, the outer portion of whichengages discs 72 and 74 and 76 and 78 so as to mount track 82 on thediscs. The end plates are joined by marginal lateral members 90 and 92,termed half bed joint dividers which may be welded, bolted, or otherwisesecured to end plates 86. The half bed joint divided 92 which is nearestforward lateral frame member 56 when the track section is in the lowerflattened portion of track 82, is shorter in height than the half bedjoint divider 90 which is nearest rear lateral frame member 56, so as toprevent tipping or cocking of the brick embedded in concrete C as thetrack section moves from the lowerportion of track'82 to the rearportion thereof.

End plates 86 are also joined by a plurality of full bed joint dividers94 which extend laterally between the end plates intermediate the halfbed joint dividers. The half bed joint dividers are joined by aplurality of longitudinal head joint plates 96 which extend between thehalf bed joint dividers 90 and 92 intermediate end plates 86 to form thelattice of the track section. The interception of the full bed jointdividers 94 and the head joint plates 96 may be effected by cutting awayhalf of each member and joining the members in the manner of an eggcrate divider, or by other means. A plurality of pins 266 are aflixed toflange 88 on one side of track section 84 and extend outwardlytherefrom. One such pin, located in the center of the compartment, isprovided for each row or course of compartments 85 of track section 84so that in the track section shown in FIG. 9, three pins are provided oneach flange. These pins are used to control the operation of surfacingmachine 20.

The height of half'bed joint divider 90, full bed joint dividers 94 andhead joint plates 96 depends on the size of brick B used in theconstruction of panel P and the position of the lower flattened portionwith respect to the exposed surface of wet concrete and may be equal,greater, or less than, the height of brick B.

By altering the configuration of the compartments 85 formed by the beddividers and head joint plates, the bricks may be deposited in theconcrete in any desired manner so that the surface of the finished panelresembles a desired bond configuration. It will be appreciated that asthe bond of the brick B is not needed for the structural integrity ofpanel P, numerous artistic or decorative patterns, not normallyavailable in brick construction, may be provided.

Track sections 84 are linked together at either side by hinges 98, shownin detail in FIG. 6, to form track 82. Hinge plates 100 forming thehinges are attached to the inner edges of end plates 86, which may berecessed to receive the hinge plates. A hinge pin 102 is insertedthrough hinge plates 100. The hinge plates 100 are formed so that thecenter of hinge pin 102 is in alignment with, or positioned slightlybelow, the bottom of end plates 86 as shown in FIG. 6.

Also as shown in FIG. 6, only a small gap exists between the flange 88of two adjacent track sections 84 when the sections are in alignment, asfor example, when the track sections are positioned in the upper orlower flattened portions of track 82. A similarly small gap existsbetween half bed joint divider 92 of one track section and the half bedjoint divider 90 of the succeeding track section. The half bed jointdividers may be constructed of thin material so that the thickness ofthe two half bed joint dividers, plus the gap between them 6 equals thethickness of a full .lbed jointdivided 94, there by causing all of thebed. joints of the finished panel to be equal in thickness. I I 1 Track82 also serves to couple surfacing machine 20 to form 22. The end plates86 of eachtrack section 84 contain a depression or hole 89in the flange88 that engages projections 42 on the upper edges of vertical sidewalls26 and .28 to form 22 when the track section is located in the lowerflattened portion of the track, as shown in FIG. 5. The holes 89 inadjacent track sections 84 and projections 42 are spaced equal distancesapart for this purpose. The discs, such as disc 78, rest on flanges 88so as to support frame 50 and the remainder of surfacing machine 20. Thediscs may rest on flanges 88 directly over holes 89 and projections 42so as to eliminate any bending moment on the flange, as shown in FIG..5. The engagement of projections 42 in holes 89 serves to accuratelylocate surfacing machine 20 in the desired vertical andhorizontal-position with respect to form 22 and the exposed surface ofthe concrete lying therein. The weight of surfacing machine 20 istransferred to projections 42 by the abutment of discs 72 through 78 onflanges 88, as shown in FIGS. 3 and 5. A pair of casters, one of whichis indicated by the numeral 169 in FIG. 1, and bearing on the upper edgeof sidewall 26, may be provided on transverse member 58 to lessen theweight of surfacing machine 20 applied to the track sections by discs 76and 78, so as to assist the track sections 84 in turning up and arounddiscs 72 and 74. Casters 171 may be provided at the front of surfacingmachine 20 for the same purpose. The engagement of projections 42 inhole 89 also aids in the movement of surfacing machine 20 along form 22in a manner hereinafter described.

The bricks are retained in track sections 84 until deposited in theconcrete in form 22 by a retaining means. Such means includes a plate104 lying beneath the upper flattened portion of track 82 to prevent thebrick from falling through the compartments of track sections 84. Plate104 is mounted on frame 52 by supports 106 fastened to the frame. Theplate extends arcuately downward at the forward end of surfacing machine20 to approximately the horizontal radii of discs 72 and 74 so as toprevent the bricks from falling through the track sections until theyhave attained a vertical position.

The retaining means of surfacing machine 20 also keeps the bricks fromfalling out of the track sections after they have moved passed thehorizontal radii of discs 72 and 74. For this purpose, the meansincludes a plurality of spring plates mounted in rows in thefront ofbrick laying machine 20, as seen most clearly in FIG. 2. One plate isprovided for each stack of bricks in the track 82. The plates may beformed from steel or other like resilient or spring-like material. Theupper row of plates 108 engages the bricks as they assume the verticalposition and presses them against the arcuate portion of plate 104. Themiddle row of plates 110 retains the bricks in track section 84 as theyturn under discs 72 and 74 and the lower row of plates 112 retains thebrick in a track section until they are deposited in the concrete inform 22.

The upper, middle, and lower rows of plates are secured to shafts 114which are rigidly mounted in the frame 52 by supports 116, 118, and 120.

While the figures show retaining means 104 as a single plate andretaining means 108, 110 and 112 as a plurality of plates, each of theretaining means may be of either construction, as desired.

Thus retaining means 112 may be formed as a single plate 1121 as shownin. FIG. 12, having a plurality of longitudinal extending bars 101aflixed thereto. The bars 101 are positioned on plate 1121 so as to liein vertical alignment with head joint dividers 96 as the track sectionspass over the plate. One end of a leaf spring 103 is at- 7 tached toeither 'sideof bars; 101 so thatthe other ends of thetwo leaf springs.103. attachedto the same-bar 101 are laterally displaced an equidistantamount from bar 101. The two-leaf. springs' attached to the'same barsform a generally .V. shaped configuration. A single leaf spring 105' isattached to either longitudinal edge'of plate 1121. The leaf springs'103and 105 serve'to insure that the bricks Bare laterally centered incompartments 85 asthey aredeposited on the-wet surface of theconcrete Cthereby insuring that the'head joints between the bricks in the panelare equal in size. The: use of a retainingplate 1121 is particularlyadvantageous if thelateraldimensions of the bricks are 'lessthan thelateral dimensions-of compartments 85.: v v As the tracksections 84 turnunder discs 72 and 74, the bricks fall partially out of compartments 85and rest on the forward-portionof'plate 1121. As the bricks moverearwardly along plate, 1:121 ,2the.bricks.pass between the leaf springs103 and: 105, flexing springs 103 toward each other and springs 105toward the edges of. plate 1121. The flexure; of the springs providesoppositely applied lateral ,forces on each brick: in the course passingbetween the springs, which. forces centerthe bricks in the compartmentsof the track section so that they are deposited on the concrete withequal lateral spacing and head joints between them.

Other retaining means, such as a plurality of belts having portionsthereof abuting the track sections may be used in place of the plate 104and plates 108, 110, and 112.

Surfacing machine 20 is driven by a drive means attached to forwardlateral member 56. The drive means is mounted on plate 122 affixed tomember 56 and having frames 124 and 126 for supporting the variouspillow blocks and journals of the drive means.

An electric motor 128 is mounted on plate 122 having a gear box coupledto the output shaft thereof. The output shaft of gear box 130 drivesjack shaft 132 through pulleys 134 and 136 and belt 138. Jack shaft 132,in turn, rotates drive shaft 140 through sprockets 142 and 144 and chain146. Sprockets 148 and 150 are mounted on the ends of drive shaft 140 todrive axle 60 through chains 162 and 164 and sprockets 166 and 168.

The rotation of axle 60 rotates discs 72 and 74 causing those discs tomove forward within track 82. This forward movement causes the tracksections 84 near forward lateral frame member 56 in the front of theupper flattened portion of track 82 to turn down and under discs 72 and74 to form part of the lower flattened portion of track 82 and to bepositioned so that holes 89 engage projections 42 on form- 22.Thesevtrack sections remain stationary with respect to form 22,positioned horizontally and vertically on the forms by projections 42,as surfacing machine 20 passes forward over them. As the track sectionsbecome adjacent rear lateral frame member 58, they are raised up andaround. discs. 7-6 and 78 and returned to the upper flattened portion.Surfacing machine 20 may move forward onform22 at a speed ofapproximately 30 inches per minute.

If desired, the casters 171 or some other element of surfacing machine20 engaging concrete form 22, may be driven by the drive means to propelthe machine along the form. 1

. A vibrating means is included in brick laying machine 20 for embeddingthe bricks B in a layer of concrete C in form 22 by vibrating them intothe surface. The elements of the vibratingmeans are shown in FIGS. 2, 3,4, 7- and 10. Apneumatic system for controlling the operation of thevibrating means'is shown in FIG. 8.

The vibrating means is designed for insertion into the compartments oftrack sections 84 to push the bricks out of the track sections 84 oftrack 82 and embed them in the surface of the concrete. For thispurpose, the vibrating means includes a vibrator head plate 170 whichextends across substantially thewidth of the track 82. The

vibrator head plate is located abovethe lower flattened portion of track82. The upper surface-of vibrator head plate 170 contains a pair ofL-shaped metal bars 172 and 174 which extend beyond either end of theplate. The L-shaped portions 176 and 178 of bars 172 and 174 extendvertically of plate 170-and mount the vibrator head plate 170 on frame50 for vertical movement with respect to the frame and the lowerflattened portion of track 82, as hereinafter .described.

i Vibrator head plate 170 contains a vibrator 180 which may be mountedon anadditional set of bars 182. Bars 172, 174, and 182 serve to stilfenvibrator head plate 170 against the vibrations generated by vibrator180. While vibrator 180 may be of any common type, an electric solenoid,solid impact type is presently preferred. Such a vibrator consists of aslug of soft iron 184 (see FIG. 3) positioned inside an electric coil'186. The magnetic field created by the coil when energized withalternating current raises the soft iron slug up and then drives itdownwardly into the vibrator head plate. It has been found that the typeof vibrator that simply raises the slug and allows it to descend of itsown weight provides vibrations insuflicient in magnitude for use in thepresent brick laying machine because of the stiffness of the concrete inwhich the bricks are embedded. The rotating type of vibrator employingan eccentrically loaded shaft or other rotating means has a tendency tocause lateral and longitudinal oscillations in the vibrating means sothat it moves over the surface of the brick rather than driving thebrick directly downward into the concrete.

A plurality of probers 188 are aflixed to the bottom of vibrator headplate 170 so as to be simultaneously insertable into four adjacent rowsof compartments of track sections 84 when vibrator head plate islowered. The probers 188 drive the brick out of the track sections andembed the bricks. B in concrete C by means of the vibrations generatedby vibrator 180, as shown in FIG. 4. Such probers may comprise channelmembers having a length and width slightly less than the length andwidth of the compartments of track section 84. One prober is providedfor each compartment in the four rows, as shown in FIGS. 2 and 3, sothat twenty-four probers are provided on vibrator head plate 170. Theprobers are arranged in four rows identified by the numerals 188a, 188b,1880, and 188d, as shown in FIG. 7, and are positioned on vibrator headplate 170 so as to be centered in the compartments of track sections 84when vibrator head plate 170 is lowered. Probers 18811 are locatednearest forward lateral frame member 56 and the forward end of surfacingmachine 20. The probers may be affixed to the bottom of vibrator headplate 170 as by welding. The depth of the probers from the bottom of thehead plate to the end of the channel members may be slightly greaterthan the height of the bed joint dividers 94 and head joint plates 96 oftrack sections 84 so that when the probers 188 are inserted all the wayinto the compartment 85 of track sections 84, and vibrator head plate170 rests on the upper surface of the track sections 84 in the lowerflattened portion of track 82, the bottom of the channel member isslightly below the lower edges of the bed dividers and head jointplates. The depth of the probers may be made greater if desired, and asthis dimension of the probers determines the amount by which the brickwill be embedded in the concrete, it must be coordinated with the heightof the projections 42 and the elevation of the concrete C in concreteform 22.

Vibrator head plate 170 is mounted on frame 50 for both vertical andhorizontal movement with respect thereto. As noted above, the tracksections in the lower flattened portion of track 82 moves rearwardlywith respect to frame 50 so that vibrator head plate 170 will also moverearwardly with respect to frame 50 when probers 188 are inserted in thecompartments of track sections 84. To maintain continuous operation ofsurfacing machine 20, vibrator head plate 170 must :be raised so thatprobers 188 are removed from the compartments of track sections 84,returned to a forward position, and then lowered so that the probers 188are inserted into a different set of compartments 85 of the tracksections 84. The vibrating head plate 170 is then moved rearwardly bythe movement of frame 50 again.

To provide the necessary vertical and horizontal movement to vibratorhead plate 170, a stationary side plate 190 may be affixed to the insideof longitudinal members 52 and 54 intermediate axles 60 and 62, as shownin FIG. 7. The plates are fastened to the frame members by means ofbolts 191 which are inserted through the plates at slots 194 on eithervertical edge of the plates and tightened. Slots 194 permit limitedhorizontal movement of side plates 190 with respect to frame members -2and 54, so that the position of vibrator head plate 170 may be adjusted,as hereinafter described.

Stationary side plates 190 contain upper and lower pairs of rollers 196and 198, rotatably mounted thereon. Sliding side plates 200 haveparallel rods extending from the upper and lower edges thereof to engagerollers 196 and 198 so that sliding side plates 200 may be reciprocallymoved in a longitudinal direction along stationary side plates 190 andlongitudinal frame members 52 and 54.

A pair of vertical vibrator head plate guides 202 are fastened tosliding side plates 200, as by bolts 204 so that the L portions of bars172 and 174 of vibrator head plate 170 fit between the guides forvertical movement with respect to sliding side plate 200. An elevatingshaft bracket 206 is afiixed to the inner surface of vibrating headplate guides 202 for movement with sliding side plate 200 and to enclosethe guide path for the L portions of bars 172 and 174. Elevating shaftbracket 206 includes notch 207 which allows vibrator head plate 170 tobe raised.

Pillow blocks 208, mounted on the upper surfaces of elevating shaftbrackets 206, journal elevator shaft 210 which extends laterally acrossframe 50 parallel to axles 60 and 62. Elevator shaft 210 contains a pairof pulleys 212 to which one end of chains 214 are afiixed. The other endof chains 214 are fixed to vibrating head plate 170 so that by rockingor partially rotating elevator shaft 210, vibrating head plate 170 maybe raised or lowered.

Such partial rotation of shaft 210 may be provided by a rack and pinionmechanism, the pinion 216 of which is mounted on one end of shaft 210and the rack 218 of which may be affixed to the end of piston 220 of aircylinder 222 fastened to flange 209 of elevating shaft bracket 206. Bypneumatically extending piston 220 and by retracting piston 220 by meansof spring 221, rack 218 is moved, pinion 216 rotated, and vibrating headplate 170 raised and lowered. A guide roller 224 may be provided toassist the movement of rack 218.

Rearward horizontal movement of vibrator head plate 170 is provided byinserting probers 188 in the compartments '85 of track sections 84 sothat the vibrator head plate is carried rearwardly by the rearwardmovement of the track sections with respect to frame 50. Forwardhorizontal movement of vibrator head plate 170, when it is in the raisedposition, so that probers 188 are removed from compartments 85, isprovided by air cylinders 226 and 228 mounted on the inside of framemembers 52 and 54 and having extensible piston rods 230 and 232, theends of which bear on sliding side plates 200. By pneumaticallyextending piston rods 230 and 232, sliding head plate 200 may be movedforward with respect to frame 50. Such forward movement may terminate atstop 233 mounted on frame 50 against which vibrator head plate is heldby the extended piston rods 230 and 233. The amount of such forwardmovement may be slightly greater than the longitudinal dimension of thecompartments in track section 84. Piston rods 230 and 232 may beretracted and moved out of abutment with sliding side plates 200 bysprings 231 and 232.

Air cylinder 222, which raises and lowers vibrator head plate 170, andair cylinders 226 and 228, which move vibrating head plate 170 forward,are energized and controlled by the pneumatic system shown in FIG. 8.The air system is powered by a source of compressed air, such ascompressor234. Compressor 234- supplies compressed air in pipe 236 to Tconnector 238 which, in turn, provides the compressed air to air lines240 and 241.

Air line 240 is connected to valve 242 which is operated by a sensingmeans 244, mounted on frame 54 and which is responsive to the positionof vibrator head plate 170 with respect to frame 50. Specifically,sensing means 244 may be mounted on frame member 54 so as to engageelevating shaft bracket 206 when the elevating shaft bracket and slidingside plate 200 have moved to a rearward position along frame member 54.

When sensing means 244 is actuated, valve 242 is Opened to allow air toenter air line 246 having check valve 248 interposed therein. Theconnection of sensing means 244 to valve 242 is indicated by the dottedline. The air in air line 246 operates air cylinder 222 to raisevibrator head plate 170 by means of rack 218 and pinion 216. Exhaustvalve 250 is closed during this operation, as indicated in FIG. 8.

Air line 241 is connected to three-way valve 252 having an exhaustoutlet 254 and a pressure outlet 256. The pressure outlet 256 isconnected to air lines 258 and 260 which supply air cylinders 226 and228.

A sensing means 262 is positioned on elevating shaft bracket 206 so asto be actuated by striking vibrator head plate 170 as the latter israised by air cylinder 222. The actuation of sensing means 262 energizesair valve 252 to supply air from air line 241 to pressure outlet 256, asby rotating valve 252. The air pressure in pressure outlet 256 and airlines 258 and 260 operates air cylinders 226 and 228 to extend pistons230 and 232 and move sliding side plates 200 and vibrator head plate 170forward aggainst stop 233. The position of stationary side plates 190 onframe member 52 and 54 may be adjusted by means of slots 194 to insurethat vibrator head plate 170 is held firmly against stop 233 by theextended pistons 230 and 232.

The forward movement of sliding side plates 200 and vibrating head plate170 de-actuates sensing means 244, closing valve 242 and retainingpiston 220 of air cylinder 222 in the extended position. This retainsvibrator head plate 170 in the raised position.

A sensing means 264 is mounted on frame member 52 so as to be actutableby striking one of pins 266 extending from flange 88 of track sectionend plate 86. The sensing means is mounted on the frame member so as tobe actuatable when the probers 188 are centered over the compartments intrack sections 84 in the lower flattened portion of track 82. Theactuation of sensing means 264 opens exhaust valve 250 to de-energizeair cylinder 222 and retract piston 220 by means of spring 221. Theretraction of piston 220 moves rack 218 to lower vibrator head plate andreinserts probers 188 into the compartments of track section 84.Compensation may be provided, in the positioning of sensing means 264,for the continuous movement of track section 84 with respect to frame50, and particularly for that increment of movement occurring during thetime the vibrator head plate 170 is being lowered.

As vibrator head plate 170 is lowered, sensing means 262 and valve 252are de-actuated, de-energizing air cylinders 226 and 228, retracting thepistons 230 and 232 away from sliding side plates 200 by means ofsprings 269 and 271. The air in cylinders 226 and 228 is exhaustedthrough valve 252 from pressure outlet 256 to exhaust outlet 254.Sliding side plates 200 are not affected by the retraction of pistons230 and 232 because of the lack of any coupling between the members.

Vibrator head plate 170 and sliding side plates 200 are moved rearwardlywith respect to frame 50 of brick laying machine 20, along with thetrack sections 84 in which probers 188 are inserted so as to againactuate 1 1 sensing 'means 244 when the vibrator head plate attains arearwardposition, to repeat the operating cycle again.

It will be appreciated that the path of movement of vibrator headplate170', with respect'to frame 50 which carries it, is rectangular inthat the vibrtaor head plate is initially moved rearwardly alongwithtrack sections 84, then moved upwardly by air cylinder 222, thenforward by air cylinders 226 and 228 to a position hereinafter termedthe raised, forward position and finally downwardly by air cylinder 222.The mount of the forward and rearward movement of vibrator head plate170 is equal to thelongitudinal dimension of the compartment 85 of tracksections 84 so that the vibrator head plate is advanced one row orcourse of compartments 85 with each operating cycle.

The sensing means and air valves may be electrically operated devices,as for example, electrical limit switches and solenoid operated airvalves or may be mechanically operated,.or linked.

OPERATION OF THE SURFACING MACHINE The surfacing machine shown in theattached drawing employs pressed brick split in half so as to utilizetwo finished surfaces of the brick thereby reducing the cost of thebrick required for the panel. The brick may be split by a masonry saw,or other means, along the center line of the brick and a diameter of theholes in the brick. The split bricks B are placed in the compartments 85of the track sections 84 in the upper flattened portion of track 82 at afirst station along the orbital path of the track, with the finishedsurfaces lying on retaining means 104 and the split surfaces exposed, asshown in FIG. 1.

Motor 128 is then energized to commence the operation of surfacingmachine 20. Vibrator 180 may also be energized at this time. Motor 128rotates axle 60 and discs 72 and 74 through the machine drive means.Rotation of axle 60 moves frame 50 forward with respect to track 82 soas to place additional track sections 84 on projections 42 at the frontedge of the machine while removing track sections from projections 42 atthe rear of the machine. Surfacing machine 20 moves along the verticalside walls 26 and 28 of form 22 by the engagement of projections 42 inholes 89 in flanges 88 of track section end plates 86.

The track sections 84 in the upper flattened portion of track 82containing the split brick B are moved toward the forward end ofsurfacing machine 20 and drawn downwardly and around discs 72 and 74. Asthe track sections 84 attain a vertical position across the front ofsurfacing machine 20, the bricks b are retained in the track sections byspring plates 108. When the track sections move under discs 72 and 74,the bricks B are retained in the track sections by spring plates 110 and112.

As the bricks B in the track sections reach the end of spring plates112, they fall onto the exposed surface of the concrete C, a row at atime, so as to rest thereon while still being partially retained withinthe track section 84 forming the lower flattened portion of track 82.This point may hereinafter be termed the second station along theorbital path of track 82. The retention of the bricks in track sections84 serves to position the rows or courses of brick against displacementalong the surface of the concrete C in accordance with the dimensions ofthe bed joint dividers and head joint plates of the track sections 84.The track sections 84 do not move with respect to form 22 because of theengagement of holes 89 on projections 42.

As surfacing machine 20 continues to move forward, along form 22, thecourses of brick deposited on the surface of the concrete C moverearwardly with respect to the machine. The first row, or course, ofbricks B eventually reaches a position in which the bricks are directlyunder the first row of probers 188a when vibrator head plate 170 is inthe raised, forward position. This may occur when five to six courses ofbricks B have been deposited on the surface of concrete C. At thispoint, sensing means 264 strikes one of pins 266, actuating the sensingmeans and de-energizing air cylinder 222 to lower the vibrator headplate 170, so that the first row of prob ers 188a descends to strike thefirst course of brick B. The vibrations generated by vibrator 180 inprobers 188a and the weight of head plate 170 embeds the first course ofbrick into the surface of the concrete.

The surfacing machine continues to move forward along form 22-to depositadditional courses of bricks b on the exposed surface of concrete C. Thetrack sections 84 forming the lower flattened portion of track 82continue to move rearwardly with respect to frame 50 of the machine.Vibrator head plate 170 is carried rearwardly with respect to frame 50'by track sections 84 due to the engagement of probers 188a in thecompartments of track sections 84. When vibrator head has movedrearwardly a distance equal to the longitudinal dimension of thecompartments of track section 84, elevator shaft bracket 206 actuatessensing means 244 to energize air cylinder 222 and raise vibrator headplate 170. Probers 188a disengage the first course of brick B on thesurface of concrete C. When vibrator head plate 170 has been raised,sensing means 262 is actuated to cause air cylinders 226 and 228 to movethe vibrator head plate 170 forward a distance equal to the longitudinaldimension of the compartments 85 so that the vibrator head plate 170 isreturned to the forward, raised position. The vibrator head plate 170 isthus moved forward with respect to the courses of brick B lying on thesurface of concrete C in form 22 to place the first row of probers 188aover the second course of brick B. When the vibrating plate 170 ispositioned so that the probers are again centered over the compartments85 of track section 84, sensing means 264 is actuated by another of pins266 to de-energize air cylinder 222 and lower vibrator head plate 170.Due to the forward movement of vibrator head plate 170 the first row ofprobers 188a now descends to strike the second course of brick B tovibrate that course into the surface of the concrete.

The second row of probers 18811 on the vibrator head plate 170 descendsonto the first course of brick so as to revibrate it into the surface ofthe concrete and to prevent those bricks from rising as the second rowof brick is vibrated into the concrete. It will be appreciated that asthe courses of brick are embedded in the exposed surface of theconcrete, the surface of the concrete has a tendency to rise due to thedisplacement of the concrete by the bricks. Thus, as the second row ofbricks is embedded in the concrete, the first row has a tendency to risealong with the concrete. The revibration of the first course of brick bythe second row of probers 188b counteracts this tendency.

Further movement of surfacing machine 20 repeats the above operatingcycle of the vibrating means so that during the third operating cyclethe first row of probers 188a of the vibrator head plate 170 descends tostrike the third course of brick B lying on the surface of the concreteC in concrete form 22. The second row of probers 18811 revibrates thesecond course of brick B while the third row of probers 188a againrevibrates the first course of brick to restore it to its initialposition as the third course of brick is embedded in the concrete.

Additional forward movement of surfacing machine 20 again repeats theabove operating cycle so that the first row of probers 188a engages thefourth course of brick on the surface of the concrete C when vibratorhead plate 170 is lowered. The second, third, and fourth rows of probers188b, 1880, and 188d, revibrates the third, second and first courses ofbrick to retain them in their embedded positions.

At the beginning of the fifth operating cycle of the vibrating means ofthe machine, when the first row of probers 188a engages the fifth courseof brick, the second third, and fourth rows of probers188b, 188C, and188d revibrate the fourth,- third, and second courses of brick B. Thefirst course of brick B is no longer revibrated, that course, and thesurface of the concrete surrounding it, beingsufficiently far removedfrom the point where the fifth row of brick is being embedded in thesurface of the concrete as to beunaffected by such embedment, and havingbeen securely positioned in the surface of the concrete byfoursuccessive applications of the probers 188 of vibrator headplate 170. Inthe case of a panel P utilizing split pressed brick Bhavingsemi-circular depressions along the split surface, the bricks mustbe embedded in the exposed surface of the concrete to an extent suchthat the semi-circulardepressions are completely below the surface ofthe concrete so as to prevent waterfrom accumulating-in the depressionsand causing freeze damage. In a typical instance, such bricks B will beembedded onehalf inch in concrete C. vAssurfacing machine 20 moves alongform 22, each course of brick deposited on the surface of the concreteis subjected to thesame treatment as described above, that is, it isinitially vibrated into position by vibrator head plate 170 and thefirst row of probers 188a and then retained in that position by threere-applications of the probers 188 of vibrator head plate 170. Thecourses of brick undergo a decreasing vertical displacement with eachsuccessive vibration to arrive at their final position at the end offour operatingcyclesof vibrator head plate 170. As a course of brick andthe track section '84 which formerly carried it approach the rear ofbricklaying machine 20, the track section is pivoted up and away bydiscs 76 and 78. The shortened height of half bed joint dividers 92 andthe location of hinge pin 102iin alignment with the upper surface of endplates 88 of the track section 84 allows the track section to sopivotwithout tipping the course of brickdirectlybelow the third or rearrow of compartments in the track section. Track sections 84 then returnto the upper flattened portion of track 82 to be reloaded withadditional quantities of split brick B. t V t I THE METHOD Themanufacture of a panel P in accordance with the present invention isinitiated by moving surfacing machine 20 to a rearward position alongform 22. The bulkheads 29 are inserted in form 22, spaced apart by adistance equal in length to the desired length of the finished panel.Collapsible cores 30 are inserted through bulkheads 29 and into concreteform 22 so as to lie parallel with vertical side walls 26 and 28.Turnbuckles 40 are adjusted to extend side plates 36 and 38 and expandcores 30. Reinforcing rods or prestressing strands and the like may beinserted in form 22, if desired, as may brackets BR.

Form 22 is then filled with the cementitious material, such as concreteC. The material must be of a consistency such that it is thin enough toallow the brick to be embedded therein by the vibrations generated byvibrator 180 and the weight of vibrator head plate 170, yet firm enoughto support and prevent displacement of the bricks once they have beenembedded in the desired position. In this regard and using concrete as aspecific example, it has been found that concrete having a consistencysuch that it forms a four inch slump is most desirable. The term slumpis utilized in the art as a measure of concrete consistency. A frustumof wet concrete twelve inches high, six inches in diameter at thebottom, and two inches in diameter at the top is formed and the amountby which the height of the frustum falls is measured. This distance,measured in inches, is termed the slump. A concrete frustum of four inchslump falls four inches in height. By way of comparison, wet concretehaving a two to three inch slump is commonly used in the manufacture ofprecast, prestressed bridge girders while concrete having a five inchslump is used in ordinary concrete work and for concrete cast directlyin place at the job site. The amount 14 of slump in wet concrete isdetermined by its ingredients. For example, large quantities of fineaggregates, such as sand, decrease the slump whereas large quantities ofcoarse aggregate increase the slump. The greater the amount of water inthe wet concrete, the greater the slump.

Concrete C having the desired slump is poured into form 22 and struckoff to the desired elevation. The elevation at which the concrete isstruck must be correlated to the height of projections 42 and the depthof probers 188 so that surfacing machine 20 is positioned the correctdistance above the exposed surface of the concrete in the form and thebricks are embedded in the concrete the desired amount. As thedepression of the brick into the surface of the concrete causes acorresponding rise in the level of the concrete surface, it is essentialthat the concrete in the form be accurately struck off at the desiredlevel.

After the concrete C is struck off in form 22, the courses of brick Bare deposited on the exposed surface and embedded therein, as by theoperation of surfacing machine 20 in the above described manner. Whencourses of bricks have been deposited along the entire length ofconcrete C in form 22, surfacing machine 20 may be placed aside for theremainder of the manufacturing process.

It is generally desirable to complete panel P by inserting mortar Mbetween bricks B so as to give the completed panel the look of aconventionally laid brick wall and to seal the surface of the panel. Theinsertion of this mortar may be done in many ways, the following methodbeing, at present, considered preferred.

A conventional brick motar is mixed, as from portland cement, lime, andsand. A small amount of water is added so that the resulting mortar isvery dry. Sufficient water is added to the mortar so that it barelyforms, and remains in, a ball when compressed by hand.

The mortar M so formulated is then shoveled over the entire surface ofthe completed panel, after which the surface is scraped to remove theexcess mortar from the courses of bricks and insert it in the jointsbetween the bricks. The surface of the bricks may be swept to furtherclean the exposed faces of the bricks.

A mortar frame, which may comprise a track section 84, having a half bedjoint dividers replaced with full bed joint dividers, is then placedover the panel so that the bed joint dividers and head joint plates liein the bed and head joints of the bricks in the panel. A vibrator, whichmay be similar to vibrator 180, is applied to the mortar frame tovibrate or tamp the mortar down to the proper elevation. The mortarframe and vibrator are moved about the panel so that each bed joint andhead joint in the panel is tamped, after which the mortar frame andvibrator may be removed.

If desired, additional mortar may be applied to the joints so as to makethem flush with the surface of the brick. The joints may also be tooledto form a concave, weather, V or other desired joint, either by handtools, or by shaping the bottom of the head joint dividers and headjoint plates to the desired configuration.

After the joints have been mortared, the panel is covered wtih awaterproof material and partially cured by the application of heat. Aheated fluid such as steam may be inserted in the cores 30 to initiatethe curing of the concrete adjacent the cores. The cores 30 are thencollapsed and removed from the form and panel and the panel removed fromthe form. The panel is then fully cured by the reapplication of heat.

We claim:

1. A method for manufacturing a panel having a plurality of brick-likeobjects arranged in a predetermined, ordered pattern of rows, theobjects being embedded in an exposed surface of cementitious materialcapable of supporting the objects, said method comprising the steps of:

forming a confined bed of cementitious material having an exposedsurface;

placing the objects in a compartmented endless track in a plurality ofsuccessive traverse rows having the predetermined, ordered pattern at afirst station removed from the exposed surface of the bed of material;conveying the rows of objects in the track in seriatim between the firststation and a second station wherein the rows are located over theexposed surface by orbitally moving the track; sequentially partiallydischarging the rows of objects from the compartments of the track atthe second station to deposit them on the exposed material surface whileretaining them in the predetermined pattern against displacement alongthe exposed surface;

sequentially completely ejecting the deposited objects from thecompartment and partially embedding them in the surface of the material;and

allowing the material to harden.

2. The method of claim 1 wherein the step of conveying the rows isfurther defined as conveying the rows of objects in a manner such thatthe rows enter the path of movement of the track at the first stationone row at a time and wherein the step of sequentially partiallydischarging the objects is further defined as sequentially partiallydischarging the objects one row at a time and depositing the row on theexposed material surface.

3. The method of claim 1 wherein the step of sequentially ejecting theobjects is further defined as applying vibratory blows to the objects todrive them out of the compartments and into the exposed surface of thebed of material.

4. The method of claim 3 wherein the step of sequentially ejecting thedeposited objects is further defined as applying vibratory blows to agiven row of objects to drive it into the exposed surface Whilesimultaneously reapplying vibratory blows to an adjacent, previouslydeposited row of objects to prevent its displacement upon the embedmentof said given row.

5. The method of claim 1 wherein the step of moving the rows of objectsis further defined as moving the rows of objects in a semi-orbital pathfrom the first station to the second station.

6. The method of claim 1 wherein the step of forming the bed of materialis further defined as providing a form having internal dimensionscorrespondingto'the desired dimensions of said finished panel andpouring the material into said form; T

7. The method of claim 6 wherein said material is concrete and whereinthe step of forming the concrete is further defined as including thestep of compounding'a concrete mixture having approximately a 4" slumpand forming a bed thereof. 9 p v 1 8. The method of claim 1 wherein saidobjects "are bricks and including-the step of splitting the brick priorto placing the bricks in the track. t

9. The method of claim 1 wherein the pattern of rows includes spacesbetween the objects and said method-includes the step of insertingmortar in-the spaces between the partially embeddedobjects.

10. The methodof claim 9 including the steps of distributing the mortarover the exposed surface of the bed of material and the partiallyembedded objects, scraping the mortar off the surface of the partiallyembedded objects into the 'spaces therebetween, tamping the mortar intothe spaces and allowing the mortar to harden. 11. The method of claim10including the step of tooling'the mortar after insertion in the spacesto give the spaces the appearance of mortared joints.

References Cited UNITED STATES PATEN S 3,629,384 12/1971 Elgenstierna264 261 3,469,000 9/1969 Smith 264-69 X 3,359,354 12/1967 Johnson 26435X 2,296,453 9/1942 Satfert 264-256X 857,581 6/1907 Boyle 264-3143,012,901 12/1961 Reese 264-70X 3,203,069 8/1965 Wogulis er al. 26 4-261x I OTHER REFERENCES Frost et ah: Modern Practical Brickworkj Batsford,

London (1956), pp. -55, 59, 276 and 277 relied on.

ROBERT F. WHITE, Primary Examiner w. E. HOAG, Assistant Examiner

